Pumping system with two way communication

ABSTRACT

A pumping system including a pump, a motor coupled to the pump, an automation system, and a pump controller located remotely from the automation system. The pump controller is coupled to at least one pump and the motor, and the pump controller is in digital communication with the motor, the automation system, and at least one auxiliary device. The pump controller transmits data to, and receives data from, the automation system and at least one auxiliary device over at least one communication link and operates the motor based on information entered into the automation system and received from the automation system. The pump controller selectively alters an operation of the motor based on the information received from one of the automation system or parameters received from the at least one auxiliary device. During a lockout state, the pump controller selects one of ignoring, delaying, or rescheduling a water

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/247,755, filed Dec. 22, 2020, which is a continuation of U.S. patentapplication Ser. No. 12/973,732, filed Dec. 20, 2010, which is acontinuation of U.S. patent application Ser. No. 11/608,860, filed Dec.11, 2006, which is a continuation-in-part of U.S. patent applicationSer. No. 11/286,888, filed Nov. 23, 2005 and a continuation-in-part ofU.S. patent application Ser. No. 10/926,513, filed Aug. 26, 2004, theentire disclosures of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to control of a pump, and moreparticularly to control of a variable speed pumping system for a pool.

BACKGROUND OF THE INVENTION

Conventionally, a pump to be used in a pool is operable at a finitenumber of predetermined speed settings (e.g., typically high and lowsettings). Typically these speed settings correspond to the range ofpumping demands of the pool at the time of installation. Factors such asthe volumetric flow rate of water to be pumped, the total head pressurerequired to adequately pump the volume of water, and other operationalparameters determine the size of the pump and the proper speed settingsfor pump operation. Once the pump is installed, the speed settingstypically are not readily changed to accommodate changes in the poolconditions and/or pumping demands.

Conventionally, it is also typical to equip a pumping system for use ina pool with auxiliary devices, such as a heating device, a chemicaldispersion device (e.g., a chlorinator or the like), a filterarrangement, and/or an automation device. Often, operation of aparticular auxiliary device can require different pump performancecharacteristics. For example, operation of a heating device may requirea specific water flow rate or flow pressure for correct heating of thepool water. It is possible that a conventional pump can be manuallyadjusted to operate at one of a finite number of speed settings inresponse to a water demand from an auxiliary device. However, adjustingthe pump to one of the settings may cause the pump to operate at a ratethat exceeds a needed rate, while adjusting the pump to another settingmay cause the pump to operate at a rate that provides an insufficientamount of flow and/or pressure. In such a case, the pump will eitheroperate inefficiently or operate at a level below that which is desired.

Thus, operation of the pump at particular performance characteristicscould optimize energy consumption. For example, two-way communicationbetween the pool pump and various auxiliary devices could to permit thepump to alter operation in response to the various performancecharacteristics required by the various auxiliary devices. Therefore, byallowing the pool pump to communication with the various auxiliarydevices, the pump could satisfy the demand for water while optimizingthe overall system energy consumption.

Accordingly, it would be beneficial to provide a pump that could bereadily and easily adapted to communicate with various auxiliary devicesto provide a suitably supply of water at a desired pressure to poolshaving a variety of sizes and features. Further, the pump should beresponsive to a change of conditions (i.e., a clogged filter or thelike), user input instructions, and/or communication with the auxiliarydevices.

SUMMARY OF THE INVENTION

In accordance with one aspect, the present invention provides a pumpingsystem including a pump, a motor coupled to the pump, an automationsystem, and a pump controller located remotely from the automationsystem. The pump controller is coupled to at least one pump and themotor, and the pump controller is in digital communication with themotor, the automation system, and at least one auxiliary device. Thepump controller transmits data to, and receives data from, theautomation system and at least one auxiliary device over at least onecommunication link and operates the motor based on information enteredinto the automation system and received from the automation system. Thepump controller selectively alters an operation of the motor based onthe information received from one of the automation system or parametersreceived from the at least one auxiliary device. During a lockout state,the pump controller selects one of ignoring, delaying, or rescheduling awater operation requested from one of the automation system or the atleast one auxiliary device.

In accordance with another aspect, the present invention provides apumping system including a pump, a motor coupled to the pump, a controlsystem including a remote keypad and display, and a pump controllerlocated remotely from the control system. The pump controller is coupledto at least one pump and the motor, and the pump controller is indigital communication with the motor and the control system. The pumpcontroller transmits data to, and receives data from, the control systemover at least one communication link, and the pump controller operatesthe motor based on information entered into the remote keypad andreceived from the control system. The pumping system performs a numberof turnovers of at least one pool and a spa over a specified timeperiod, and an amount of water movement is associated with operation ofat least one auxiliary device. The pumping system considers the amountof water movement in determining whether the number of turnovers overthe specified time period is achieved.

In accordance with another aspect, the present invention provides apumping system including a pump, a motor coupled to the pump, a controlsystem, the control system including a remote keypad and display, and apump controller located remotely from the control system. The pumpcontroller is coupled to at least one pump and the motor, the pumpcontroller is in digital communication with the motor and the controlsystem, and the pump controller transmits data to and receives data fromthe control system over at least one communication link. The pumpcontroller operates the motor based on information entered into theremote keypad and received from the control system, and the informationreceived from the control system includes an operational state includingat least one of a filtration mode, a vacuum mode, and a heating mode.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and, other features and advantages of the presentinvention will become apparent to those skilled in the art to which thepresent invention relates upon reading the following description withreference to the accompanying drawings, in which:

FIG. 1 is a block diagram of an example of a variable speed pumpingsystem in accordance with the present invention with a pool environment;

FIG. 2 is another block diagram of another example of a variable speedpumping system in accordance with the present invention with a poolenvironment;

FIG. 3 is a schematic illustration of example auxiliary devices that canbe operably connected to an example means for controlling the motor;

FIG. 4 is similar to FIG. 3, but shows various other example auxiliarydevices;

FIG. 5 is a perceptive view of an example pump unit that incorporatesthe present invention;

FIG. 6 is a perspective, partially exploded view of a pump of the unitshown in

FIG. 5; and

FIG. 7 is a perspective view of an example means for controlling thepump unit shown in FIG. 5.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Certain terminology is used herein for convenience only and is not to betaken as a limitation on the present invention. Further, in thedrawings, the same reference numerals are employed for designating thesame elements throughout the figures, and in order to clearly andconcisely illustrate the present invention, certain features may beshown in somewhat schematic form.

An example variable-speed pumping system 10 in accordance with oneaspect of the present invention is schematically shown in FIG. 1. Thepumping system 10 includes a pump unit 12 that is shown as being usedwith a pool 14. It is to be appreciated that the pump unit 12 includes apump 16 for moving water through inlet and outlet lines 18 and 20.

The swimming pool 14 is one example of a pool. The definition of“swimming pool” includes, but is not limited to, swimming pools, spas,and whirlpool baths, and further includes features and accessoriesassociated therewith, such as water jets, waterfalls, fountains, poolfiltration equipment, chemical treatment equipment, pool vacuums,spillways and the like.

A water operation 22 is performed upon the water moved by the pump 16.Within the shown example, water operation 22 is a filter arrangementthat is associated with the pumping system 10 and the pool 14 forproviding a cleaning operation (i.e., filtering) on the water within thepool. The filter arrangement 22 is operatively connected between thepool 14 and the pump 16 at/along an inlet line 18 for the pump. Thus,the pump 16, the pool 14, the filter arrangement 22, and theinterconnecting lines 18 and 20 form a fluid circuit or pathway for themovement of water.

It is to be appreciated that the function of filtering is but oneexample of an operation that can be performed upon the water. Otheroperations that can be performed upon the water may be simplistic,complex or diverse. For example, the operation performed on the watermay merely be just movement of the water by the pumping system (e.g.,re-circulation of the water in a waterfall or spa environment).

Turning to the filter arrangement 22, any suitable construction andconfiguration of the filter arrangement is possible. For example, thefilter arrangement 22 can include a sand filter, a cartridge filter,and/or a diatomaceous earth filter, or the like. In another example, thefilter arrangement 22 may include a skimmer assembly for collectingcoarse debris from water being withdrawn from the pool, and one or morefilter components for straining finer material from the water. In stillyet another example, the filter arrangement 22 can be in fluidcommunication with a pool cleaner, such as a vacuum pool cleaner adaptedto vacuum debris from the various submerged surfaces of the pool. Thepool cleaner can include various types, such as various manual and/orautomatic types.

The pump 16 may have any suitable construction and/or configuration forproviding the desired force to the water and move the water. In oneexample, the pump 16 is a common centrifugal pump of the type known tohave impellers extending radially from a central axis. Vanes defined bythe impellers create interior passages through which the water passes asthe impellers are rotated. Rotating the impellers about the central axisimparts a centrifugal force on water therein, and thus imparts the forceflow to the water. Although centrifugal pumps are well suited to pump alarge volume of water at a continuous rate, other motor-operated pumpsmay also be used within the scope of the present invention.

Drive force is provided to the pump 16 via a pump motor 24. In the oneexample, the drive force is in the form of rotational force provided torotate the impeller of the pump 16. In one specific embodiment, the pumpmotor 24 is a permanent magnet motor. In another specific embodiment,the pump motor 24 is an induction motor. In yet another embodiment, thepump motor 24 can be a synchronous or asynchronous motor. The pump motor24 operation is infinitely variable within a range of operation (i.e.,zero to maximum operation). In one specific example, the operation isindicated by the RPM of the rotational force provided to rotate theimpeller of the pump 16. In the case of a synchronous motor 24, thesteady state speed (RPM) of the motor 24 can be referred to as thesynchronous speed. Further, in the case of a synchronous motor 24, thesteady state speed of the motor 24 can also be determined based upon theoperating frequency in hertz (Hz).

A means for controlling 30 provides for the control of the pump motor 24and thus the control of the pump 16. Within the shown example, the meansfor controlling 30 can include a variable speed drive 32 that providesfor the infinitely variable control of the pump motor 24 (i.e., variesthe speed of the pump motor). By way of example, within the operation ofthe variable speed drive 32, a single phase AC current from a sourcepower supply is converted (e.g., broken) into a three-phase AC current.Any suitable technique and associated construction/configuration may beused to provide the three-phase AC current. The variable speed drivesupplies the AC electric power at a changeable frequency to the pumpmotor to drive the pump motor. The construction and/or configuration ofthe pump 16, the pump motor 24, the means for controlling 30 as a whole,and the variable speed drive 32 as a portion of the means forcontrolling 30, 130 are not limitations on the present invention. In onepossibility, the pump 16 and the pump motor 24 are disposed within asingle housing to form a single unit, and the means for controlling 30with the variable speed drive 32 are disposed within another singlehousing to form another single unit. In another possibility, thesecomponents are disposed within a single housing to form a single unit.

Further still, the means for controlling 30 can receive input from auser interface 31 that can be operatively connected to the means forcontrolling 30 in various manners. For example, the user interface 31can include a keypad 40, buttons, switches, or the like such that a usercould input various parameters into the means for controlling 30. Inaddition or alternatively, the user interface 31 can be adapted toprovide visual and/or audible information to a user. For example, theuser interface 31 can include one or more visual displays 42, such as analphanumeric LCD display, LED lights, or the like. Additionally, theuser interface 31 can also include a buzzer, loudspeaker, or the like.Further still, as shown in FIG. 5, the user interface 31 can include aremovable (e.g., pivotable, slidable, detachable, etc.) protective cover44 adapted to provide protection against damage when the user interface31 is not in use. The protective cover 44 can include various rigid orsemi-rigid materials, such as plastic, and can have various degrees oflight permeability, such as opaque, translucent, and/or transparent.

The pumping system 10 can have additional means used for control of theoperation of the pump. In accordance with one aspect of the presentinvention, the pumping system 10 includes means for sensing,determining, or the like one or more parameters indicative of theoperation performed upon the water. Within one specific example, thesystem includes means for sensing, determining or the like one or moreparameters indicative of the movement of water within the fluid circuit.

The ability to sense, determine or the like one or more parameters maytake a variety of forms. For example, one or more sensors 34 may beutilized. Such one or more sensors 34 can be referred to as a sensorarrangement. The sensor arrangement 34 of the pumping system 10 wouldsense one or more parameters indicative of the operation performed uponthe water. Within one specific example, the sensor arrangement 34 sensesparameters indicative of the movement of water within the fluid circuit.The movement along the fluid circuit includes movement of water throughthe filter arrangement 22. As such, the sensor arrangement 34 includesat least one sensor used to determine flow rate of the water movingwithin the fluid circuit and/or includes at least one sensor used todetermine flow pressure of the water moving within the fluid circuit. Inone example, the sensor arrangement 34 is operatively connected with thewater circuit at/adjacent to the location of the filter arrangement 22.It should be appreciated that the sensors of the sensor arrangement 34may be at different locations than the locations presented for theexample. Also, the sensors of the sensor arrangement 34 may be atdifferent locations from each other. Still further, the sensors may beconfigured such that different sensor portions are at differentlocations within the fluid circuit. Such a sensor arrangement 34 wouldbe operatively connected 36 to the means for controlling 30 to providethe sensory information thereto.

It is to be noted that the sensor arrangement 34 may accomplish thesensing task via various methodologies, and/or different and/oradditional sensors may be provided within the system 10 and informationprovided therefrom may be utilized within the system. For example, thesensor arrangement 34 may be provided that is associated with the filterarrangement and that senses an operation characteristic associated withthe filter arrangement. For example, such a sensor may monitor filterperformance. Such monitoring may be as basic as monitoring filter flowrate, filter pressure, or some other parameter that indicatesperformance of the filter arrangement. Of course, it is to beappreciated that the sensed parameter of operation may be otherwiseassociated with the operation performed upon the water. As such, thesensed parameter of operation can be as simplistic as a flow indicativeparameter such as rate, pressure, etc.

Such indication information can be used by the means for controlling 30via performance of a program, algorithm or the like, to perform variousfunctions, and examples of such are set forth below. Also, it is to beappreciated that additional functions and features may be separate orcombined, and that sensor information may be obtained by one or moresensors. With regard to the specific example of monitoring flow rate andflow pressure, the information from the sensor arrangement 34 can beused as an indication of impediment or hindrance via obstruction orcondition, whether physical, chemical, or mechanical in nature, thatinterferes with the flow of water from the pool to the pump such asdebris accumulation or the lack of accumulation, within the filterarrangement 34.

The example of FIG. 1 shows an example additional operation 38 and theexample of FIG. 2 shows an example additional operation 138. Such anadditional operation (e.g., 38 or 138) may be a cleaner device, eithermanual or autonomous. As can be appreciated, an additional operationinvolves additional water movement. Also, within the presented examplesof FIGS. 1 and 2, the water movement is through the filter arrangement(e.g., 22 or 122). Such, additional water movement may be used tosupplant the need for other water movement, as will be discussed furtherherein.

Within another example (FIG. 2) of a pumping system 110 that includesmeans for sensing, determining, or the like one or more parametersindicative of the operation performed upon the water, and the means forcontrolling 130 can determine the one or more parameters via sensing,determining or the like parameters associated with the operation of apump 116 of a pump unit 112. Such an approach is based upon anunderstanding that the pump operation itself has one or morerelationships to the operation performed upon the water.

It should be appreciated that the pump unit 112, which includes the pump116 and a pump motor 124, a pool 114, a filter arrangement 122, andinterconnecting lines 118 and 120, may be identical or different fromthe corresponding items within the example of FIG. 1. In addition, asstated above, the means for controlling 130 can receive input from auser interface 131 that can be operatively connected to the controllerin various manners.

Keeping with the example of FIG. 2, some examples of the pumping system110, and specifically the means for controlling 30, 130 and associatedportions, that utilize at least one relationship between the pumpoperation and the operation performed upon the water attention are shownin U.S. Pat. No. 6,354,805, to Moller, entitled “Method For Regulating ADelivery Variable Of A Pump” and U.S. Pat. No. 6,468,042, to Moller,entitled “Method For Regulating A Delivery Variable Of A Pump.” Thedisclosures of these patents are incorporated herein by reference. Inshort summary, direct sensing of the pressure and/or flow rate of thewater is not performed, but instead one or more sensed or determinedparameters associated with pump operation are utilized as an indicationof pump performance. One example of such a pump parameter is inputpower. Pressure and/or flow rate can be calculated/determined from suchpump parameter(s).

Although the system 110 and the means for controlling 30, 130 there maybe of varied construction, configuration and operation, the functionblock diagram of FIG. 2 is generally representative. Within the shownexample, an adjusting element 140 is operatively connected to the pumpmotor and is also operatively connected to a control element 142 withinthe controller 130. The control element 142 can operate in response to acomparative function 144, which receives input from a power calculation146.

The power calculation 146 is performed utilizing information from theoperation of the pump motor 124 and controlled by the adjusting element140. As such, a feedback iteration is performed to control the pumpmotor 124. Also, it is the operation of the pump motor and the pump thatprovides the information used to control the pump motor/pump. Asmentioned, it is an understanding that operation of the pump motor/pumphas a relationship to the flow rate and/or pressure of the water flowthat is utilized to control flow rate and/or flow pressure via controlof the pump.

As mentioned, the sensed, determined (e.g., calculated, provided via alook-up table, graph or curve, such as a constant flow curve or thelike, etc.) information can be utilized to determine the variousperformance characteristics of the pumping system 110, such as inputpower consumed, motor speed, flow rate and/or the flow pressure. In oneexample, the operation can be configured to prevent damage to a user orto the pumping system 10, 110 caused by an obstruction. Thus, the meansfor controlling (e.g., 30 or 130) provides the control to operate thepump motor/pump accordingly. In other words, the means for controlling(e.g., 30 or 130) can repeatedly monitor one or more performancevalue(s) 146 of the pumping system 10,110, such as the input powerconsumed by, or the speed of, the pump motor (e.g., 24 or 124) to senseor determine a parameter indicative of an obstruction or the like.

Turning now to FIGS. 3-4, in accordance with an aspect of the presentinvention, the pumping system 10, 110 can include one or more auxiliarydevices 50 operably connected to the means for controlling 30, 130. Asshown in FIGS. 3-4, the auxiliary devices 50 can include variousdevices, including mechanical, electrical, and/or chemical devices, thatcan be connected to the means for controlling 30, 130 in variousmechanical and/or electrical manners. In one example, the auxiliarydevices 50 can include devices configured to perform an operation uponthe water moved by the water pump 12, 112. Various examples can includea water heating device 52, a chemical dispersion device 54 fordispersing chemicals into the water, such as chlorine, bromine, ozone,etc., and/or a water dispersion device 56, such as a water fountain orwater jet. Further examples can include a filter arrangement 58 forperforming a filtering operation upon the water, a second water pump 60with a second pump motor 62 for moving the water, and/or a vacuum 64device, such as a manual or automatic vacuum device for cleaning theswimming pool.

In another example, the auxiliary devices 50 can include a userinterface device capable of receiving information input by a user, suchas a parameter related to operation of the pumping system 10, 110.Various examples can include a remote keypad 66, such as a remote keypadsimilar to the keypad 40 and display 42 of the means for controlling 30,a personal computer 68, such as a desktop computer, a laptop, a personaldigital assistant, or the like, and/or an automation control system 70,such as various analog or digital control systems that can includeprogrammable logic controllers (PLC), computer programs, or the like.The various user interface devices 66, 68, 70, as illustrated by theremote keypad 66, can include a keypad 72, buttons, switches, or thelike such that a user could input various parameters and information. Inaddition or alternatively, the user interface devices 66, 68, 70 can beadapted to provide visual and/or audible information to a user, and caninclude one or more visual displays 74, such as an alphanumeric LCDdisplay, LED lights, or the like, and/or a buzzer, loudspeaker, or thelike (not shown). Thus, for example, a user could use a remote keypad 66or automation system 70 to monitor the operational status of the pumpingsystem 10, 110.

In still yet another example, the auxiliary devices 50 can includevarious miscellaneous devices for interaction with the swimming pool.Various examples can include a valve 76, such as a mechanically orelectrically operated water valve, an electrical switch 78, a lightingdevice 80 for providing illumination to the swimming pool and/orassociated devices, an electrical or mechanical relay 82, a sensor 84,including but not limited to those sensors 34 discussed previouslyherein, and/or a mechanical or electrical timing device 86. In additionor alternatively, the auxiliary device 50 can include a communicationpanel 88, such as a junction box, switchboard, or the like, configuredto facilitate communication between the means for controlling 30, 130and various other auxiliary devices 50. The various miscellaneousdevices can have direct or indirect interaction with the water of theswimming pool and/or any of the various other devices discussed herein.It is to be appreciated that the various examples discussed herein andshown in the figures are not intended to provide a limitation upon thepresent invention, and that various other auxiliary devices 50 can beused.

The pumping system 10, 110 can also include means for providing two-waycommunication between the means for controlling 30, 130 and the one ormore auxiliary devices 50. The means for providing two-way communicationcan include various communication methods configured to permitinformation, data, commands, or the like to be input, output, processed,transmitted, received, stored, and/or displayed in a two-way exchangebetween the means for controlling 30, 130 and the auxiliary devices 50.It is to be appreciated that the means for providing two-waycommunication can provide for control of the pumping system 10, 110, orcan also be used to provide information for monitoring the operationalstatus of the pumping system 10, 110.

The various communication methods can include half-duplex communicationto provide communication in both directions, but only in one directionat a time (e.g., not simultaneously), or conversely, can include fullduplex communication to provide simultaneous two-way communication.Further, the means for providing two-way communication can be configuredto provide analog communication, such as through a continuous spectrumof information, or it can also be configured to provide digitalcommunication, such as through discrete units of data, such as discretesignals, numbers, binary numbers, non-numeric symbols, letters, icons,or the like.

In various digital communication schemes, the means for providingtwo-way communication can be configured to provide communication throughvarious digital communication methods. In one example, the means forproviding two-way communication can be configured to provide digitalserial communication. As such, the serial communication method can beconfigured to send and receive data one unit at a time in a sequentialmanner. Various digital serial communication specifications can be used,such as RS-232 and/or RS-485, both of which are known in the art. TheRS-485 specification, for example, can include a two-wire, half-duplex,multipoint serial communication protocol that employs a specifieddifferential form of signaling to transmit information. In addition oralternatively, the digital serial communication can be used in amaster/slave configuration, as is known in the art. Various otherdigital communication methods can also be used, such as parallelcommunications (e.g., all the data units are sent together), or thelike. It is to be appreciated that, despite the particular method used,the means for providing two-way communication can be configured topermit any of the various connected devices to transmit and/or receiveinformation.

The various communication methods can be implemented in various manners,including customized cabling or conventional cabling, including serialor parallel cabling. In addition or alternatively, the communicationmethods can be implemented through more sophisticated cabling and/orwireless schemes, such as over phone lines, universal serial bus (USB),firewire (IEEE 1394), ethernet (IEEE 802.03), wireless ethernet (IEEE802.11), bluetooth (IEEE 802.15), WiMax (IEEE 802.16), or the like. Themeans for providing two-way communication can also include varioushardware and/or software converters, translators, or the like configuredto provide compatibility between any of the various communicationmethods.

Further still, the various digital communication methods can employvarious protocols including various rules for data representation,signaling, authentication, and error detection to facilitate thetransmission and reception of information over the communicationsmethod. The communication protocols for digital communication caninclude various features intended to provide a reliable exchange of dataor information over an imperfect communication method. In the example ofRS-485 digital serial communication, an example communication protocolcan include data separated into categories, such as device address data,preamble data, header data, a data field, and checksum data.

The means for providing two-way communication can be configured toprovide either, or both, of wired or wireless communication. In theexample of RS-485 digital serial communication having a two-wiredifferential signaling scheme, a data cable 90 can include merely twowires, one carrying an electrically positive data signal and the othercarrying an electrically negative data signal, though various otherwires can also be included to carry various other digital signals. Asshown in FIGS. 5 and 7, the means for controlling 30, 130 can include adata port 92 for connection to a data cable connector 94 of the datacable 90. The data cable 90 can include a conventional metal wire cable,though it could also include various other materials, such as a fiberoptic cable. The data cable 90 can be shielded to protect from externalelectrical interferences, and the data cable connector 94 can includevarious elements to protect against water and corrosion, such as a waterresistant, twist lock connector. The data port 92 can even include aprotective cover 95 or the like for use when the data cable 90 isdisconnected. Further still, the various auxiliary devices 50 can beoperably connected to the means for controlling 30, 130 directly orindirectly through various data cables 91.

In addition or alternatively, the means for providing two-waycommunication can be configured to provide analog and/or digitalwireless communication between the means for controlling 30 and theauxiliary devices 50. For example, the means for controlling 30, 130and/or the auxiliary devices can include a wireless device 98, such as awireless transmitter, receiver, or transceiver operating on variousfrequencies, such as radio waves (including cellular phone frequencies),microwaves, or the like. In addition or alternatively, the wirelessdevice 98 can operate on various visible and invisible lightfrequencies, such as infrared light. As shown in FIG. 4, the wirelessdevice 98 can be built in, or provided as a separate unit connected byway of a data cable 93 or the like.

In yet another example, at least a portion of the means for providingtwo-way communication can include a computer network 96. The computernetwork 96 can include various types, such as a local area network(e.g., a network generally covering to a relatively small geographicallocation, such as a house, business, or collection of buildings), a widearea network (e.g., a network generally covering a relatively widegeographical area and often involving a relatively large array ofcomputers), or even the internet (e.g., a worldwide, public and/orprivate network of interconnected computer networks, including the worldwide web). The computer network 96 can be wired or wireless, aspreviously discussed herein. The computer network 96 can act as anintermediary between one or more auxiliary devices 50, such as apersonal computer 68 or the like, and the means for controlling 30, 130.Thus, a user using a personal computer 68 could exchange data andinformation with the means for controlling 30, 130 in a remote fashionas per the boundaries of the network 96. In one example, a user using apersonal computer 68 connected to the internet could exchange data andinformation (e.g., for control and/or monitoring) with the means forcontrolling 30, 130, from home, work, or even another country. Inaddition or alternatively, a user could exchange data and informationfor control and/or monitoring over a cellular phone or other personalcommunication device.

In addition or alternatively, where at least a portion of the means forproviding two-way communication includes a computer-network 96, variouscomponents of the pumping system 10, 110 can be serviced and/or repairedfrom a remote location. For example, if the pump 12, 112 or means forcontrolling 30, 130 develops a problem, an end user can contact aservice provider (e.g., product manufacturer or authorized servicecenter, etc.) that can remotely access the problematic component throughthe means for providing two-way communication and the computer network96 (e.g., the internet). Alternatively, the pumping system 10, 110 canbe configured to automatically call out to the service provider when aproblem is detected. The service provider can exchange data andinformation with the problematic component, and can service, repair,update, etc. the component without having a dedicated service personphysically present in front of the swimming pool. Thus, the serviceprovider can be located at a central location, and can provide serviceto any connected pumping system 10, 110, even from around the world. Inanother example, the service provider can constantly monitor the status(e.g., performance, settings, health, etc.) of the pumping system 10,110, and can provide various services, as required.

As stated previously herein, the means for controlling 30, 130 can beadapted to control operation of the pump 12, 112 and/or the variablespeed motor 24, 124. The means for controlling 30, 130 can alteroperation of the variable speed motor 24, 124 based upon variousparameters of the pumping system 10, 110, such as water flow rate, waterpressure, motor speed, power consumption, filter loading, chemicallevels, water temperature, alarms, operational states, or some otherparameter that indicates performance of the pumping system 10, 110. Itis to be appreciated that the sensed parameter of operation may beotherwise associated with the operation performed upon the water, and/orcan even be independent of an operation performed upon the water. Assuch, the sensed parameter of operation can be as simplistic as a flowindicative parameter such as rate, pressure, etc., or it can involveindependent parameters such as time, energy cost, turnovers per day,relay or switch positions, etc. The parameters can be received by themeans for controlling 30, 130 in various manners, such as through thepreviously discussed sensor arrangements 34, user interfaces 31, 131and/or the means for providing two-way communication.

Regardless of the methodology used, the means for controlling 30, 130can be capable of receiving a parameter from one or more of theauxiliary devices 50 through the various means for providing two-waycommunication discussed herein. In one example, the means forcontrolling 30, 130 can be operable to alter operation of the motor 24,124 based upon the parameter(s) received from the auxiliary device(s)50. For example, where a water heater 52 requires a particular waterflow rate for proper operation, the means for controlling 30, 130 couldreceive a desired water flow rate parameter from the water heater 52through the means for providing two-way communication. In response, themeans for controlling 30, 130 could alter operation of the motor 24, 124to provide the requested water performance characteristics.

However, it is to be appreciated that the means for controlling 30, 130can also be capable of independently controlling the variable speedmotor 24, 124 without receipt of a parameter from the auxiliarydevice(s) 50. That is, the means for controlling 30, 130 could operatein a completely autonomous fashion based upon a predetermined computerprogram or the like, and/or can receive parameters from operablyconnected sensor arrangements 34 or the like. In addition oralternatively, the means for controlling 30, 130 can receive parametersfrom the onboard user interface 31, 131 and can selectively alteroperation of the motor 24, 124 based upon the parameters received.

Additionally, where the means for controlling 30, 130 is capable ofindependent operation, it can also be operable to selectively alteroperation of the motor 24, 124 based upon the parameters received fromthe auxiliary device(s) 50. Thus, the means for controlling 30, 130 canchoose whether or not to alter operation of the motor 24, 124 when itreceives a parameter from an auxiliary device 50, such as a desiredwater flow rate from a water heater 52 or a user input parameter from aremote user interface device 66. For example, where the pumping system10, 110 is performing a particular function, such as a backwash cycle,or is in a lockout state, such as may occur when the system 10, 110cannot be primed, the means for controlling 30, 130 can choose to ignorea water flow rate request from the heater 52. In addition oralternatively, the means for controlling 30, 130 could choose to delayand/or reschedule altering operation of the motor 24, 124 until a latertime (e.g., after the backwash cycle finishes).

Thus, the means for controlling 30, 130 can be configured to controloperation of the variable speed motor 24, 124 independently, or inresponse to parameters received. However, it is to be appreciated thatthe means for controlling 30, 130 can also be configured to act as aslave device that is controlled by an automation system 70, such as aPLC or the like. In one example, the automation system 70 can receivevarious parameters from various auxiliary devices 50, and based uponthose parameters, can directly control means for controlling 30, 130 toalter operation of the motor 24, 124. It is to be appreciated that themeans for controlling 30, 130 can be configured to switch betweenindependent control and slave control. For example, the means forcontrolling 30, 130 can be configured to switch between the controlschemes based upon whether the data cable 90 is connected (e.g.,switching to independent control when the data cable 90 isdisconnected).

Turning to the issue of operation of the pumping system 10,110 over acourse of a long period of time, it is typical that a predeterminedvolume of water flow is desired. For example, it may be desirable tomove a volume of water equal to multiple turnovers within a specifiedtime period (e.g., a day). Within an example in which the wateroperation includes a filter operation, the desired water movement (e.g.,specific number of turnovers within one day) may be related to thenecessity to maintain a desired water clarity.

Thus, in accordance with another aspect of the present invention, themeans for controlling 30, 130 can be configured to optimize a powerconsumption of the motor 24, 124 based upon the parameter(s) receivedfrom the auxiliary device(s) 50. Focusing on the aspect of minimalenergy usage (e.g., optimization of energy consumed over a time period),within some known pool filtering applications, it is common to operate aknown pump/filter arrangement for some portion (e.g., eight hours) of aday at effectively a very high speed to accomplish a desired level ofpool cleaning. However, with the present invention, the system 10,110with an associated filter arrangement 22,122 can be operatedcontinuously (e.g., 24 hours a day, or some other time amount(s)) at anever-changing minimum level to accomplish the desired level of poolcleaning. It is possible to achieve a very significant savings in energyusage with such a use of the present invention as compared to the knownpump operation at the high speed. In one example, the cost savings wouldbe in the range of 90% as compared to a known pump/filter arrangement.

Associated with operation of various functions and auxiliary devices 50is a certain amount of water movement. Energy conservation in thepresent invention is based upon an appreciation that such other watermovement may be considered as part of the overall desired watermovement, cycles, turnover, filtering, etc. As such, water movementassociated with such other functions and devices can be utilized as partof the overall water movement to achieve desired values within aspecified time frame (e.g., turnovers per day). Thus, control of a firstoperation (e.g., filtering) in response to performance of a secondoperation (e.g., running a pool cleaner) can allow for minimization of apurely filtering aspect. This permits increased energy efficiency byavoiding unnecessary pump operation.

Accordingly, the means for controlling 30, 130 can determine an optimalenergy consumption for the motor 24, 124 over time based upon theparameter(s) received from the auxiliary device(s) 50 and associatedfirst, second, etc. operations. In one example, the motor 24, 124 can beoperated at a minimum water flow rate required to maintain adequatewater filtration until a higher flow rate is required by a differentwater operation. In another example, based upon the various waterperformance characteristics required by each auxiliary device 50, themeans for controlling 30, 130 can determine in which order to performthe first, second, etc. operations, or for how long to perform theoperations. In addition or alternatively, the means for controlling 30,130 can optimize operation of the motor 24, 124 based upon actualperformance data received from the auxiliary device(s) 50. For example,where a filter arrangement 22, 122 has become clogged over time andrequires an ever-increasing water flow or pressure, the means forcontrolling 30, 130 could choose to simultaneously operate various otherauxiliary devices 50 that require high water flow rates (e.g., a heater52 or the like). Similarly, the means for controlling 30, 130 couldchoose to delay various operations based upon receipt of actualperformance data. For example, where a filter arrangement 22, 122 hasbecome clogged over time and requires an ever-increasing water flow orpressure, the means for controlling 30, 130 could choose to delayoperation of an automatic pool cleaner 64 until after the filterarrangement 22, 122 has been cleaned.

It is to be appreciated that the means for controlling (e.g., 30 or 130)may have various forms to accomplish the desired functions. In oneexample, the means for controlling 30, 130 includes a computer processorthat operates a program. In the alternative, the program may beconsidered to be an algorithm. The program may be in the form of macros.Further, the program may be changeable, and the means for controlling30, 130 is thus programmable. It is to be appreciated that theprogramming for the means for controlling 30, 130 may be modified,updated, etc. through the means for providing two-way communication.

Also, it is to be appreciated that the physical appearance of thecomponents of the system (e.g., 10 or 110) may vary. As some examples ofthe components, attention is directed to FIGS. 5-7. FIG. 5 is aperspective view of the pump unit 12 and the means for controlling 30for the system 10 shown in FIG. 1. FIG. 6 is an exploded perspectiveview of some of the components of the pump unit 12. FIG. 7 is aperspective view of the means for controlling 30.

In addition to the foregoing, a method of controlling the pumping system10, 110 for moving water of a swimming pool is provided. The pumpingsystem 10, 110 includes the water pump 12, 112 for moving water inconnection with performance of an operation upon the water and thevariable speed motor 24, 124 operatively connected to drive the pump 12,112. The method comprises the steps of providing means for controlling30, 130 the variable speed motor 24, 124, providing an auxiliary device50 operably connected to the means for controlling 30, 130, andproviding two-way communication between the means for controlling 30,130 and the auxiliary device 50. The method also includes the steps ofreceiving a parameter to the means for controlling 30, 130 from theauxiliary device 50 through the two-way communication, and selectivelyaltering operation of the motor 24, 124 based upon the parameter. Inaddition or alternatively, the method can include any of the variouselements and/or operations discussed previously herein, and/or evenadditional elements and/or operations.

It should be evident that this disclosure is by way of example and thatvarious changes may be made by adding, modifying or eliminating detailswithout departing from the scope of the teaching contained in thisdisclosure. As such it is to be appreciated that the person of ordinaryskill in the art will perceive changes, modifications, and improvementsto the example disclosed herein. Such changes, modifications, andimprovements are intended to be within the scope of the presentinvention.

1. A pumping system comprising: a pump; a motor coupled to the pump; anautomation system; and a pump controller located remotely from theautomation system, the pump controller coupled to at least one of thepump and the motor, the pump controller in digital communication withthe motor, the automation system, and at least one auxiliary device, thepump controller transmitting data to and receiving data from theautomation system and the at least one auxiliary device over at leastone communication link, the pump controller operating the motor based oninformation entered into the automation system and received from theautomation system, wherein the pump controller selectively alters anoperation of the motor based on the information received from one of theautomation system or parameters received from the at least one auxiliarydevice, and during a lockout state, the pump controller selects one ofignoring, delaying, or rescheduling a water operation requested from oneof the automation system or the at least one auxiliary device.
 2. Thepumping system of claim 1, wherein the pump controller alters theoperation of the motor based on one or more of parameters received froma sensor arrangement and parameters received from the at least oneauxiliary device.
 3. The pumping system of claim 1, wherein theinformation entered into the automation system is entered into theautomation system via a user interface.
 4. The pumping system of claim1, wherein the at least one communication link includes a wireless link.5. The pumping system of claim 1, wherein the at least one communicationlink includes at least one computer network, the at least one computernetwork including at least one of a local area network, a wide areanetwork, and the Internet.
 6. The pumping system of claim 1, wherein theat least one communication link provides at least one of half-duplex andfull-duplex communication.
 7. The pumping system of claim 1, wherein theinformation received from the automation system includes at least one offlow rate, pressure, motor speed, power consumption, filter loading,chemical levels, water temperature, alarms, operational states, time,energy cost, turnovers per day, and relay or switch positions.
 8. Thepumping system of claim 1, wherein the pump controller operates themotor at a minimum flow rate required to maintain adequate filtrationuntil a higher flow rate is required by a different water operation. 9.The pumping system of claim 1, wherein the at least one auxiliary deviceincludes a user interface to reprogram operating parameters.
 10. Thepumping system of claim 1, wherein the at least one auxiliary deviceincludes at least one of a water heating device, a chemical dispersiondevice, a water dispersion device, a filter, a second pump, a vacuumdevice, a valve, a switch, a lighting device, a relay, a sensor, atiming device, or a communication panel.
 11. The pumping system of claim10, wherein the at least one auxiliary device includes two auxiliarydevices and the pump controller determines which of the two auxiliarydevices to operate first and for how long.
 12. A pumping systemcomprising: a pump; a motor coupled to the pump; a control systemincluding a remote keypad and display; and a pump controller locatedremotely from the control system, the pump controller coupled to atleast one of the pump and the motor, the pump controller in digitalcommunication with the motor and the control system, the pump controllertransmitting data to and receiving data from the control system over atleast one communication link, the pump controller operating the motorbased on information entered into the remote keypad and received fromthe control system, wherein the pumping system performs a number ofturnovers of at least one of a pool and a spa over a specified timeperiod, wherein an amount of water movement is associated with operationof at least one auxiliary device, and wherein the pumping systemconsiders the amount of water movement in determining whether the numberof turnovers over the specified time period is achieved.
 13. The pumpingsystem of claim 12, wherein the pump controller is capable of operatingthe motor without receipt of the information from the control system.14. The pumping system of claim 12, wherein the pump controllertransmits an operational status of the pumping system to the controlsystem.
 15. The pumping system of claim 12, wherein the pump controllertransmits data to the control system and receives data from the controlsystem based on a serial communication specification.
 16. The pumpingsystem of claim 12, wherein the pump controller transmits problem datafor at least one component of the pumping system to the control system.17. The pumping system of claim 12, wherein the pump controller receivesservice data for at least one component of the pumping system from thecontrol system.
 18. The pumping system of claim 12, wherein the at leastone communication link includes a cable that is at least one ofinsulated, shielded, water tight, and includes two wires.
 19. A pumpingsystem comprising: a pump; a motor coupled to the pump; a controlsystem, the control system including a remote keypad and display; and apump controller located remotely from the control system, the pumpcontroller coupled to at least one of the pump and the motor, the pumpcontroller in digital communication with the motor and the controlsystem, the pump controller transmitting data to and receiving data fromthe control system over at least one communication link, the pumpcontroller operating the motor based on information entered into theremote keypad and received from the control system, wherein theinformation received from the control system includes an operationalstate including at least one of a filtration mode, a vacuum mode, and aheating mode.
 20. The pumping system of claim 19, further comprising atleast one remote auxiliary device in communication with at least one ofthe control system and the pump controller, wherein the at least oneremote auxiliary device includes a heater, wherein the informationreceived from the control system for the heating mode is that the heateris operating or needs to operate, and wherein the pump controller altersan operation of the motor to provide an increased flow rate necessaryfor proper operation of the heater.